Rack mountable power distribution apparatus

ABSTRACT

Power distribution apparatus include a rack mountable housing, an electrical power input assembly and an electrical power output assembly including a plurality of external circuits adapted for hardwired to remote equipment and a plurality of internal circuits each adapted to receive a plug of electrical equipment and to provide power thereto. The plurality of internal circuits may include differently configured receptacles adapted to receive differently configured plugs.

RELATED APPLICATIONS

This application is a continuation of U.S. Ser. No. 09/730,689, filedDec. 6, 2000, which is a continuation-in-part of U.S. patent applicationSer. No. 09/469,978 filed Dec. 21, 1999, now U.S. Pat. No. 6,608,406,the disclosure of each of which is hereby incorporated in its entiretyherein by this reference.

BACKGROUND OF THE INVENTION

The present invention generally relates to electrical power distributionapparatus, and more particularly relates to low cost, multi-function,rack mountable electrical power distribution apparatus and systems.

Research and development of computer technology has continually producedsmaller and more compact systems. However, electrical power distributionunits and systems for supplying power to electrical devices, such ascomputers and other critical equipment, in a building or other facilityhave remained bulky and sometimes difficult to work with.

Conventionally, electrical power coming into a facility passes into afree-standing power distribution unit (PDU) that includes a substantialplurality of output circuits. Each of these circuits is hard-wired tocables which are passed through conduits for distances of up to about200 feet or more, to individual components of critical equipment. Atotal conduit run of up to about 3000 feet per PDU can occur. Thiswiring is often run through floors and walls of the facility during theelectrical wiring phase of building construction. Electrical outputsinitiating from such free-standing PDUs are typically provided as cablesthat are accessible through walls and floors of the facility.

Electrical needs in a building frequently change, typically by anincrease in demand for more output circuits to accommodate more piecesof equipment. Power strips including a number of plug receptacles andhaving a single circuit breaker may be connected to a wall receptacle.However, in many cases, a power strip is not appropriate or sufficientfor large scale changes in electrical needs, or for accommodatingadditional pieces of critical equipment which requires hard-wiredconnections to the power source.

The process of re-cabling electrical output circuits from the PDU, forexample, to more strategic locations within the facility, is a costly,labor intensive task, which typically requires the work of outsidecontractors who specialize in electrical cabling and rewiring. Becauseof the inherent difficulty of accessing a specific wire or cable fromthe numerous, and sometimes tangled masses of cables and wires concealedwithin walls or floors of the facility, obsolete and unusable cables areoften left in place adding to the confusion and difficulty ofmaintaining or controlling such wiring.

Clearly, there is a need for a power distribution units and systems thataddress the concerns presented by conventional systems.

SUMMARY OF THE INVENTION

New electrical power distribution apparatus and systems have beendiscovered. The present apparatus are compact in design, cost effectiveand labor and time saving. The present apparatus and systems provideversatility and flexibility in meeting electrical power requirements inboth large and small facilities.

In one broad aspect, electrical power distribution apparatus inaccordance with the invention comprise a housing and an electrical powerinput assembly, preferably located substantially in the housing, adaptedto be connected to an electrical power supply, for example, a commercialpower supply, preferably an uninterruptible power supply or UPS, whichis provided from a conventional power source, e.g., generating plant.The apparatus, and in particular, the housing, preferably israck-mountable, for example, on a conventional 19 inch or 23 inchindustry standard rack. This rack mountable feature is highlyadvantageous in that the present apparatus is compact, can be placed ona rack for easy installation and maintenance. This rack mountablefeature provides the present apparatus with substantial benefitsrelative to conventional, free standing and large or bulky PDU's.

The apparatus in accordance with the invention further comprises aplurality of electrical power output assemblies, preferably locatedsubstantially in the housing, adapted to receive electrical power fromthe power input assembly. The power output assemblies may be mounted ina circuit panel that is removably mounted in the housing. Preferably,the plurality of output assemblies includes at least one outputconnection adapted to be hard-wired, for example, to a piece ofequipment in a manner similar to hard-wiring equipment to a conventionalpower distribution unit. The plurality of output assemblies may, andpreferably does, also include at least one output receptacle adapted toreceive an equipment plug to provide electrical power, for example, tothe equipment associated with the equipment plug. Thus, the presentapparatus are effective in coupling directly to local pieces ofequipment through conventional receptacles, as well as being hard-wiredto remote pieces of equipment, or alternatively to one or moreadditional separate power distribution apparatus in accordance with thepresent invention. It is noted that the hard-wired output connection mayhereinafter sometimes be referred to as an “external circuit”, and theoutput receptacle or receptacle circuit may hereinafter sometimes bereferred to as an “internal circuit”.

In one advantageous embodiment of the invention, the plurality of outputassemblies may include a plurality of differently configured receptaclesadapted to receive differently configured equipment plugs. This featureadvantageously adds to the flexibility of the present apparatus.

In another aspect of the invention, each of the external circuits and/orinternal circuits includes a different, individually operable circuitbreaker, although more than one circuit, such as two or more internalcircuits, can be associated with the same circuit breaker.

Unlike large, free-standing power distribution units, the presentelectrical power distribution apparatus may be adapted for receiving anddistributing single phase power, thus making it convenient for smallelectrical applications. The apparatus, however, may also be adapted foruse with a three phase power. Advantageously, the input assembly isadapted to be electrically connected to a single phase electrical powersupply, or alternately to a three phase electrical power supply.

Preferably, the electrical power input assembly further comprises ameter, for example, located substantially in the housing, adapted tomonitor at least one property of the electrical power passing throughthe input assembly. For example, the meter may be a voltage meter formonitoring voltage being provided to the apparatus. More sophisticatedmeters may be employed to provide enhanced electrical power monitoring.For example, a multi-function monitor, such as the 7300 ION-TRAN modelsold by Power Measurement, may be advantageously employed.

In addition, a transformer, for example, a step down transformer, may beprovided. The transformer preferably is adapted to be in electricalcommunication with both the electrical power supply and the inputassembly. Because of the compact nature of the present apparatus, thetransformer, which is often a substantial source of heat, preferably islocated outside the housing, for example, in the outdoors or otherenvironment where the heat produced can be effectively dissipated.

In an additional aspect of the present invention, electrical powerdistribution systems are provided. The present systems generallycomprise a plurality of electrical power distribution apparatusconfigured such that each electrical power distribution apparatus isadapted to be electrically connected with at least one of the otherelectrical power distribution apparatus. At least one, and preferablymore than one, of the electrical power distribution apparatus includedin the present systems is an apparatus in accordance with the presentinvention, for example, as described herein.

In one very useful embodiment, the present systems provide a singleprimary electrical power distribution apparatus in electricalcommunication with one or more electrical power distribution apparatusin accordance with the present invention, for example, hardwired to theprimary power distribution apparatus through an output connection of theprimary electrical power distribution apparatus. Such systems veryeffectively distribute electrical power while reducing the amount ofwiring required for such distribution. Since each of the powerdistribution apparatus included in the present systems preferably areeffective to provide both receptacle circuits and hardwired circuits,each individual power distribution apparatus making up the system isable to provide power to pieces of equipment located close to the powerdistribution apparatus, for example, using the receptacle circuits, andto pieces of equipment which are relatively remote from the powerdistribution apparatus, for example, using the output connections whichare adapted to be hardwired to such pieces of equipment. The use of thepresent power distribution apparatus in such electrical powerdistribution systems takes advantage of the flexibility and versatilityof the present electrical power distribution apparatus.

Any and all features described herein and combinations of such featuresare included within the scope of the present invention provided that thefeatures of any such combinations are not mutually inconsistent.

These and other aspects of the present invention will become apparent inthe following detailed description, particularly in conjunction with theaccompanying drawings in which like parts bear like reference numerals,primed or followed by a,b,c, etc. as appropriate.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a circuit diagram of a power distribution apparatus inaccordance with the present invention showing an electrical power inputassembly and multiple, electrical power output assemblies including bothlocal receptacles and remote output connections.

FIG. 1A is a circuit diagram of an alternative embodiment of theelectrical power input assembly portion of the power distributionapparatus of FIG. 1.

FIG. 2 is a perspective view of a partially disassembled embodiment of apower distribution apparatus in accordance with the present invention.

FIG. 3 is a back view, in perspective, of the embodiment (assembled)shown in FIG. 2.

FIG. 4 is a front view of the embodiment shown in FIGS. 2 and 3, inwhich the apparatus has been mounted to an industry standard rack.

FIG. 5 is a diagram of a power distribution system, including aplurality of power distribution apparatus, in accordance with thepresent invention.

DETAILED DESCRIPTION

Turning now to FIG. 1, a power distribution apparatus 10, in accordancewith the invention is represented by a block circuit diagram. Theapparatus 10 generally comprises an electrical power input assembly,represented generally at 14, adapted to receive power from anuninterruptible or substantially constant electrical power source orsupply 18, and a plurality of electrical power output assemblies,represented generally at 20, adapted to receive and distributeelectrical power from the input assembly 14. The power supply 18 may beprovided by a commercial power source, for example, a single phasesystem or three phase system. Neutral and ground lines 24 and 26,respectively, are shown connecting the power supply 18 to a neutral busbar 28 and a ground bus bar 30 respectively, as is conventional.

Electrical power through power input line 34 is passed through atransformer 36, of conventional design, adapted to be in electricalcommunication with both the electrical power supply 18 and the inputassembly 14. The transformer 36 is a step-down transformer adapted tostep down the voltage of the power from the power supply, for example,from 3 phase 480V AC in line 34 to 3 phase 208V AC in line 40.

The input assembly 14 includes an input circuit breaker 42 ofconventional design. The input circuit breaker 42 functions to protectapparatus 10 against surges of high voltage or high current electricalpower. In addition, a meter 50, for example, a volt meter and/or an ampmeter, may be provided for measuring at least one property of theelectrical power, for example, voltage and/or current, passing throughthe input assembly 14 along line 40. Further, a metal oxide varister, orMOV, 51 is provided in line 53 which extends from the high side of inputcircuit breaker 42 to ground bus bar 30. MOV 51, of conventional design,functions to suppress power surges from power supply 18. It is to beunderstood that transformer 36, meter 50 and MOV 51 are optional so thatapparatus including none, one, two or all three of the components areincluded within the scope of the present invention.

In one embodiment, the reliability of input assembly 14 may be enhancedby providing a plurality of power sources and, in the event of a failureof one power source, allowing the use of one or more of the other powersources. Referring now to FIG. 1A, two power sources 18 a and 18 bsupply electrical power through power input lines 34 a and 34 b to inputassembly 14′. In this embodiment, the power from the power sources 18 aand 18 b passes through a transformer 36 a or a transformer 36 b,respectively. All of the transformers 36 a and 36 b used are of the samedesign as the transformer 36 of FIG. 1 and are adapted to be inelectrical communication with both the respective electrical powersources 18 a and 18 b and the input assembly 14′. Neutral and groundlines 24′ and 26′ are shown commonly connected with the power sources 18a and 18 b, respectively, to neutral bus bar 28 and ground bus bar 30.

In this embodiment only one of the two power sources 18 a and 18 b isused to supply power at any one time. A switch 38 is provided to supplypower to line 40 at the point shown as in FIGS. 1 and 1A as PS, therebysupplying power to input circuit breaker 42. The switch may bemechanical or static (electronic) (make before break) and configured tomonitor the power and to switch from one power source to another eitherautomatically upon the failure of a power source or manually. Thisfeature provides for continuous and redundant power to the final load.The switch can be of either the interruptible type or thenoninterruptible type meaning a break-before-make switch or amake-before-break switch. The noninterruptible type of switch insures apower supply during the switchover from one power source to another,using, for example, a static switch electronically or mechanicallyoperated to provide an overlap between the two power sources or a backupbattery as an interim power supply.

Electrical meter 50 and MOV 51 may also be used with the input assembly14′ in the same manner and to the same advantage that they are used asshown in FIG. 1.

Referring again to FIG. 1, the electrical power output assemblies 20 areadapted to provide electrical power to both remote locations by cableconnections and to local electronic components and other equipment. Moreparticularly, the electrical power outputs 54 from the output assemblies20 include a plurality of output connections 56 adapted to be hard-wiredto pieces of electrical equipment, for example, main frame computer 62,in a manner similar to connecting a conventional PDU to such a piece ofequipment. Preferably, at least about eight output connections 56 areprovided, although the number can range up to about 30 or about 40 ormore.

The electrical power outputs 54 further include a plurality ofelectrical output receptacles 64 adapted to receive a pronged plug 67for providing power to a local piece of equipment, for example, apersonal computer 68, located near the apparatus 10. The number ofoutput receptacles can range up to about 40 or about 50 or more. It isnoted that the term “electrical output receptacles” is considered hereinto include various standard and non-standard plug receptacles, as wellas any suitable wiring means for connecting the power input assembly 14to such various plug receptacles. In one embodiment of apparatus 10, aplurality of differently configured receptacles, adapted to receivedifferently configured plugs, are provided.

It is to be appreciated that the present power distribution apparatus10, in accordance with the present invention, may be configured suchthat the plurality of electrical power outputs 54 include at least oneoutput, and preferably a plurality of output connections 56, adapted tobe hard wired to a remote location or equipment, and at least one outputreceptacle 64, and preferably a plurality of output receptacles 64, plugfor providing power to a local piece of equipment.

However, the output receptacles 64 may be optional. When utilizing asingle phase power supply through input assembly 14, the presentapparatus 10 offers the advantage of being a compact, for example, rackmountable, power distribution apparatus having the capability of beingconnected to remote equipment through external connections or circuits56. The apparatus 10 may thus be used as a distribution sub-systemproviding an electrical interface, or distribution center, between aconventional PDU and several components of equipment, including remote,electric equipment which is hardwired to the apparatus 10.

In one embodiment of the invention, each of the output connections 56and output receptacles 64 is associated with a different, i.e.independently operable, circuit breaker 66. Such circuit breakers 66 actor function to provide surge protection for the individual pieces ofequipment, for example, main frame computer 62 and personal computer 68,electrically connected to apparatus 10. Of course, if desired, two ormore output connections 56 or two or more output receptacles 64 can beassociated with the same output circuit breaker 66.

The invention may be more clearly understood with respect to FIGS. 2, 3and 4 which show a preferred embodiment of the apparatus 10. Theapparatus 10 preferably comprises a housing 70 made of one or moresuitable materials of construction, such as steel, aluminum, and thelike.

The apparatus further comprises a circuit panel 72 removably mountedwithin the housing 70. A bracket 73 within the housing 70 provides forsupporting the circuit panel 72, without the panel 72 being bolted orotherwise secured in place. The plurality of electrical power outputassemblies 20 are mounted in the circuit panel 72. The circuit panel 72may have a removable cover 74 (shown in partially cut away view in FIG.3), with the power input circuit breaker 42 and power output circuitbreakers 66 being made accessible through on the circuit panel cover 74,as shown. The cover 74 is mounted to the circuit panel 72 by suitableconnectors 76.

As shown in FIGS. 2 and 3, the housing 70 may have two access doors,specifically a first or front door 77 and a second or back door 78, eachpreferably including a latch 82 and hinges 83. The first door 76 enablesaccess to the circuit breakers 42 and 66.

Referring to FIG. 3, the second door 78 includes openings or apertures92 for exposing the output receptacles 64 for use. For example,differently configured apertures 92 may be defined in the door 78 toaccommodate the differently configured receptacles 64. For example, apair of apertures 92 may be used for exposing a conventionally designed,duplex receptacle 64 for receiving a three pronged plug. The interiorside 98 of second door 78, has outlet receptacles 64 mounted thereto, isshown in FIG. 2. Suitable electrical wiring is provided within thecircuit panel 72 for enabling electrical connection between contactterminals 96 of the receptacles 64 and the electrical power inputassembly 14. Such wiring and connections between the input assembly 14and the parallel output assemblies 20 is considered conventional andtherefor will not be described in detail herein.

Preferably, the housing 70 includes top and bottom panels 102, 104having knockouts 106 for enabling access to the “external” outputconnectors 56. One of the knockouts 106 may be used to provide accessfor insertion of an input cable (not shown in FIG. 2) from the powersupply 18, in which lines from a power input cable are connected tocircuit breaker 42 (through transformer 36), neutral bus or bar 28 andground bus or bar 30. It is noted that when the power supply is a threephase electrical power supply, the input circuit may include three powerinput lines (“hot” lines) carrying 208 V. For distributing power from aone or single phase power supply, two hot lines carrying 208V oralternatively 1 hot line carrying 120 V may be provided.

An important aspect of the invention is shown in FIG. 4. Morespecifically, the housing 70 is rack-mountable. For example, the housing70 may be appropriately sized, and include external mounts 110, forenabling the apparatus 10 to be mounted on a conventional 19 inch or 23inch, or other small sized, industry standard rack 112. For example, thehousing 70 may have a length, height and depth measurement of about17×19×5 inches. Fasteners, such as conventional nut/bolt combinations114 are employed to secure housing 70 to rack 112. In the embodimentshown, a power supply input cable 116 and two electrical power outputcables 118 are connected through top and bottom panels 102, 104 of thehousing 70 by suitable mounting connectors 122.

A power distribution system 210 in accordance with the present inventionis shown in block diagram in FIG. 5. Preferably, the system 210comprises a plurality of electrical power distribution apparatus 220,230, 240 and 250 made in accordance with the present invention asdescribed herein, wherein each of the apparatus 220, 230, 240 and 250receives electrical power supplied by a main power source, for example,commercial power supplied through primary power distribution unit 250.The system 210 may be used to supply and distribute electrical powerthrough a building or other facility (not shown). Each of the apparatus220, 230, 240 and 250 include multiple output connectors (externalcircuits) 261, as well as multiple output receptacles (internalcircuits) 263. It is to be appreciated that each apparatus 220, 230, 240is electrically connected to apparatus 250 through an output connector261, as shown in FIG. 5. In one embodiment, primary power distributionunit 250 can be replaced by a conventional PDU which has only hard-wiredcircuits.

The present apparatus 10 and system 210 have the capacity to meet thepower requirements and needs of both large and small facilities. As canbe appreciated, the apparatus 10 and system 210 reduce or substantiallyeliminate many of the problems associated with conventional powerdistribution units and systems. The present apparatus and systems alsogreatly facilitates trouble shooting when electrical problems arise,thereby reducing maintenance costs and employee down-time. For example,if an electrical problem arises at one workstation, the problem can bequickly tracked and investigated without the need to eliminate power toother workstations that are functioning satisfactorily. This is madepossible by means of different and separately operable circuits madeavailable through the present power distribution apparatus and systems.

While this invention has been described with respect to various specificexamples and embodiments, it is to be understood that the invention isnot limited thereto, and that it can be variously practiced within thescope of the following claims.

1. An electrical power distribution unit comprising: a rack mountablehousing having no internal battery; an electrical power input assemblylocated substantially in the housing of the power distribution unit andadapted to be electrically connected to an electrical power supply; anda circuit panel comprising a plurality of circuit breakers locatedsubstantially in the housing of the power distribution unit, and aplurality of electrical power output assemblies, each of the pluralityof electrical power output assemblies electrically connected to theelectrical power input assembly and one of the circuit breakers, andadapted to receive electrical power from the electrical power inputassembly, the plurality of electrical power output assemblies including(1) a plurality of output connections, each output connection structuredand adapted to be hard-wired to a piece of equipment to provideelectrical power, and (2) at least one receptacle connected to andspaced apart from one of the circuit breakers and adapted to receive anequipment plug to provide electrical power from the electrical powerinput assembly.
 2. The power distribution unit of claim 1, wherein theelectrical power input assembly is adapted to be electrically connectedto the electrical power supply separate and apart from the powerdistribution unit.
 3. The power distribution unit of claim 1, whereinthe housing includes a front access door and a back access door.
 4. Thepower distribution unit of claim 1, which further comprises a meterlocated within the housing and adapted to monitor at least one propertyof electrical power passing through the input assembly.
 5. The powerdistribution unit of claim 1, which further comprises a transformeradapted to be in electrical communication with both the electrical powersupply and the input assembly.
 6. The power distribution unit of claim1, wherein the input assembly is adapted to be electrically connected toa single phase electrical power supply or to a three phase electricalpower supply.
 7. The power distribution unit of claim 1, wherein theinput assembly is adapted to be electrically connected to a single phaseelectrical power supply.
 8. The power distribution unit of claim 1,wherein each of the output connections and the at least one receptacleis electrically connected to a different circuit breaker of theplurality of circuit breakers.
 9. The power distribution unit of claim1, wherein the plurality of electrical output assemblies are mounted inthe circuit panel.
 10. The power distribution unit of claim 1, whereinthe at least one of the receptacles is electrically connected to theelectric power input assembly by a wire.
 11. The power distribution unitof claim 1, wherein the plurality of output connections comprise atleast about 8 output connections.
 12. The power distribution unit ofclaim 1, which further comprises a switch structured and positioned toalternately connect and disconnect one of two or more electrical powersupplies to the electrical power input assembly.
 13. An electrical powerdistribution unit comprising: a rack mountable housing having nointernal battery; an electrical power input assembly locatedsubstantially in the housing of the power distribution unit and adaptedto be electrically connected to an electrical power supply; a circuitpanel comprising a plurality of circuit breakers located substantiallyin the housing, and a plurality of electrical power output assemblies,each of the plurality of electrical power output assemblies electricallyconnected to the electrical power input assembly, and adapted to receiveelectrical power from the electrical power input assembly, the pluralityof electrical power output assemblies including (1) at least one outputconnection electrically connected to one of the circuit breakers andstructured and adapted to be hard-wired to a piece of equipment toprovide electrical power, and (2) a plurality of receptacles, eachreceptacle being electrically connected to and spaced apart from one ofthe circuit breakers, and each receptacle being structured to receive anequipment plug to provide electrical power.
 14. The power distributionunit of claim 13, wherein the housing is adapted to be mounted on a 19inch or 23 inch rack and the electrical power input assembly is adaptedto be electrically connected to the electrical power supply separate andapart from the power distribution unit.
 15. The power distribution unitof claim 13, which further comprises a meter located within the housingand adapted to monitor at least one property of electrical power passingthrough the input assembly.
 16. The power distribution unit of claim 13,wherein each of the at least one output connection and the receptaclesis connected to a different circuit breaker of the plurality of circuitbreakers.
 17. The power distribution unit of claim 13, wherein theplurality of receptacles comprises at least about 8 receptacles.
 18. Thepower distribution unit of claim 13, which further comprises a switchstructured and positioned to alternately connect and disconnect one oftwo or more electrical power supplies to the electrical power inputassembly.
 19. The power distribution unit of claim 13, wherein theplurality of receptacles include a plurality of different configuredreceptacles for accommodating differently configured equipment plugs.